Articles comprising high melt flow ionomeric compositions

ABSTRACT

A polymeric film or sheet comprising an ionomeric composition comprising ionomeric copolymer of an alpha olefin and about 1 to about 30 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the ionomeric copolymer, wherein the carboxylic acid is neutralized to a level of 1 to 100 mol %, with one or more metal ions, based on the total number of moles of carboxylate groups in the ionomeric copolymer, and wherein the ionomeric copolymer has a Melt Index of about 20 to about 300 g/10 min. The ionomeric composition preferably comprises an additive selected from the group consisting of silane coupling agent, organic peroxide, and combinations thereof. In addition, an article comprising an interlayer formed of the polymeric film or sheet and an additional layer selected from the group consisting of glass, other polymeric interlayer sheets, polymeric film layers, and metal films or sheets. Examples of articles include safety windows and solar cells.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Appln. No.60/901,387, filed on Feb. 15, 2007, which is incorporated herein byreference in its entirety.

FIELD OF THE INVENTION

The invention relates to ionomeric compositions, polymeric films orsheets derived therefrom, and their utility in safety laminates andsolar cell modules.

BACKGROUND OF THE INVENTION

Glass laminated products have contributed to society for almost acentury. Beyond the well known, every day automotive safety glass usedin windshields, laminated glass is used in all forms of thetransportation industry. Safety glass is characterized by high impactand penetration resistance and does not scatter glass shards and debriswhen shattered.

Safety glass typically consists of a sandwich of two glass sheets orpanels bonded together with an interlayer of a polymeric sheet. One orboth of the glass sheets may be replaced with optically clear rigidpolymeric sheets, such as sheets made of polycarbonates. Safety glasshas further evolved to include multiple layers of glass and polymericsheets bonded together with interlayers of polymeric sheets.

The interlayers used in safety glass are typically made from relativelythick polymer sheets, which exhibit toughness and bondability to theglass in the event of a crack or crash. Widely used interlayer materialsinclude complex, multicomponent compositions based on poly(vinylbutyral) (PVB), poly(urethane) (PU), poly(ethylene vinyl acetate) (EVA),ionomers, and the like.

As a renewable energy resource, the use of solar cell modules is rapidlyexpanding. One preferred way of manufacturing a solar cell moduleinvolves forming a pre-laminate assembly comprising at least 5structural layers. The solar cell pre-laminates are constructed in thefollowing order starting from the top, or incident layer (that is, thelayer first contacted by light) and continuing to the backing (the layerfurthest removed from the incident layer): (1) incident layer (typicallya glass plate or a thin polymeric film (such as a fluoropolymer orpolyester film), but could conceivably be any material that istransparent to sunlight), (2) front encapsulant layer, (3)voltage-generating component (or solar cell component), (4) backencapsulant layer, and (5) backing layer.

The encapsulant layers are designed to encapsulate and protect thefragile voltage-generating component. Generally, a solar cellpre-laminate will incorporate at least two encapsulant layers sandwichedaround the solar cell component. The optical properties of the frontencapsulant layer must be such that light can be effectively transmittedto the solar cell component. Additionally, encapsulant layers generallyhave similar requirements and compositions to that described above forglazing interlayers.

The use of ionomeric compositions as threat resistant safety laminateinterlayer sheets has been known within the art (see, e.g. U.S. Pat. No.3,344,014; U.S. Pat. No. 3,762,988; U.S. Pat. No. 4,663,228; U.S. Pat.No. 4,668,574; U.S. Pat. No. 4,799,346; U.S. Pat. No. 5,759,698; U.S.Pat. No. 5,763,062; U.S. Pat. No. 5,895,721; U.S. Pat. No. 6,150,028;U.S. Pat. No. 6,432,522; US 2002/0155302; US 2002/0155302; WO 99/58334;and WO 2006/057771). For Example, U.S. Pat. No. 5,759,698 discloses aglass laminate interlayer derived from an ionomer resin which has beenthermoset with an organic peroxide and a silane agent.

The use of ionomeric compositions as solar cell encapsulant films orsheets has also been known within the art (see, e.g., U.S. Pat. No.5,476,553; U.S. Pat. No. 5,478,402; U.S. Pat. No. 5,733,382; U.S. Pat.No. 5,762,720; U.S. Pat. No. 5,986,203; U.S. Pat. No. 6,114,046; U.S.Pat. No. 6,187,448; U.S. Pat. No. 6,660,930; US 2003/0000568; US2005/0279401; JP 2000186114; and JP 2006032308).

However, the ionomeric resins being used in the art of safety laminatesor solar cell modules generally have a low melt flow index (MI) of 15g/10 min or less (2160 g, 190° C., ISO 1133, ASTM D1238). The use ofsuch low melt flow ionomeric resins requires higher laminationtemperatures (i.e., 130° C.-170° C.) and therefore may complicate thelamination process.

Chou et al., in U.S. Pat. No. 6,680,821, describe a method of coating ametallic surface using a resin powder comprising certain metalneutralized acid copolymers comprising an alpha-olefin and an alpha-betaunsaturated carboxylic acid with a MI in the range of from about 20 toabout 1,000 g/10 min. This patent does not describe use of suchmaterials within safety glass or photovoltaic module laminates oradditive packages that enhance the performance of the copolymers in suchuses.

There is a need for polymeric film or sheet suitable for use asinterlayers in glass laminate end-use applications, such as safetywindows and solar cells, that do not have the shortcomings describedabove, as well as for compositions useful in forming such films orsheets. For instance, there is a desire to prepare useful compositionswith a reduced extrusion compounding temperature. In addition, there isa desire to reduce the lamination temperature, preferably to about 100°C. to about 120° C., or to reduce the lamination cycle time, or both,and therefore simplifying the lamination process. In addition, there isa desire for films or sheets that have enhanced adhesion strength undera wide variety of lamination temperatures, including such desirablelower temperatures, and to provide the laminates with improved shockresistance.

SUMMARY OF THE INVENTION

The invention is directed to a polymeric film or sheet comprising anionomeric composition comprising ionomeric copolymer of an alpha olefinand about 1 to about 30 wt % of alpha,beta-ethylenically unsaturatedcarboxylic acid having 3 to 8 carbons, based on the total weight of theionomeric copolymer, wherein the carboxylic acid is neutralized to alevel of 1 to 100 mol %, with one or more metal ions, based on the totalnumber of moles of carboxylate groups in the ionomeric copolymer, andwherein the ionomeric copolymer has a Melt Index of about 20 to about300 g/10 min.

Preferably the ionomeric copolymer has a Melt Index of about 30 to about200 g/10 min.

Preferably the alpha olefin is ethylene.

Preferably the alpha,beta-ethylenically unsaturated carboxylic acid isselected from the group consisting of acrylic acid, methacrylic acid,itaconic acid, maleic acid, maleic anhydride, fumaric acid, monomethylmaleic acid, and mixtures thereof.

Preferably the ionomeric copolymer comprises about 10 to about 25 wt %(more preferably about 15 to about 23 wt %, and most preferably about 18to about 23 wt %) of the alpha,beta-ethylenically unsaturated carboxylicacid.

Preferably the carboxylic acid is neutralized to a level of 2 to 40(preferably to 20) mol %, with one or more metal ions, based on thetotal number of moles of carboxylate groups in the ionomeric copolymer.

The films or sheets of the invention preferably have a total thicknessof about 0.1 mil (0.003 mm) to about 250 mils (6.35 mm). In oneembodiment, the polymeric film or sheet preferably has a thickness ofabout 10 to about 250 mils (about 0.25 to about 6.35 mm). In anotherembodiment, the polymeric film or sheet preferably has a thickness ofabout 0.1 to about 10 mils (about 0.003 to about 0.25 mm). In a thirdembodiment, the thickness is preferably about 10 to about 20 mils (about0.25 to about 0.51 mm).

Preferably the ionomeric composition further comprises an additiveselected from the group consisting of silane coupling agent, organicperoxide, and combinations thereof.

In one preferred embodiment, the ionomeric composition contains about0.01 to about 5 wt % (more preferably about 0.05 to about 1 wt %) of thesilane coupling agent, based on the total weight of the ionomericcomposition. Preferably the silane coupling agent is selected from thegroup consisting of gamma-chloropropylmethoxysilane,vinyltrimethoxysilane, vinyltriethoxysilane,vinyltris(beta-methoxyethoxy)silane,gamma-vinylbenzylpropyltrimethoxysilane,N-beta-(N-vinylbenzylaminoethyl)-gamma-aminopropyltrimethoxysilane,gamma-methacryloxypropyltrimethoxysilane, vinyltriacetoxysilane,gamma-glycidoxypropyltrimethoxysilane,gamma-glycidoxypropyltriethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, vinyltrichlorosilane,gamma-mercaptopropylmethoxysilane, gamma-aminopropyltriethoxysilane,N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane, and mixturesthereof.

In another preferred embodiment, the ionomeric composition containsabout 0.01 to about 10 wt % (preferably about 0.5 to about 3 wt %) ofthe organic peroxide, based on the total weight of the ionomericcomposition. Preferably the organic peroxide is selected from the groupconsisting of 2,5-dimethylhexane-2,5-dihydroperoxide,2,5-dimethyl-2,5-di(tert-betylperoxy)hexane-3, di-tert-butyl peroxide,tert-butylcumyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane,dicumyl peroxide, alpha,alpha′-bis(tert-butyl-peroxyisopropyl)benzene,n-butyl-4,4-bis(tert-butylperoxy)valerate,2,2-bis(tert-butylperoxy)butane, 1,1-bis(tert-butyl-peroxy)cyclohexane,1,1-bis(tert-butylperoxy)-3,3,5-trimethyl-cyclohexane, tert-butylperoxybenzoate, benzoyl peroxide and mixtures thereof.

The invention is also directed to an article comprising an interlayerformed of the polymeric film or sheet and an additional layer selectedfrom the group consisting of glass, other polymeric interlayer sheets,polymeric film layers, and metal films or sheets.

By “other polymeric interlayer sheets” reference is made to aninterlayer sheet that may be the same as or different than interlayerformed of the polymeric film or sheet. Preferably the other polymericinterlayer sheets are formed of materials selected from the groupconsisting of acid copolymers and ionomers derived therefrom,poly(ethylene-co-vinyl acetate) (EVA), poly(vinyl acetal), polyurethane(PU), polyvinylchloride (PVC), polyethylenes, polyolefin blockelastomers, ethylene acrylate ester copolymers, silicone elastomers andepoxy resins. In one preferred embodiment, the other polymericinterlayer sheet is the same or substantially similar to the interlayerformed of the polymeric film or sheet.

Preferably the polymeric film layers are formed of materials selectedfrom the group consisting of polyesters, poly(ethylene naphthalate),polycarbonate, polyolefins, norbornene polymers, polystyrene,styrene-acrylate copolymers, acrylonitrile-styrene copolymers,polysulfones, nylons, poly(urethanes), acrylics, cellulose acetates,cellophane, vinyl chloride polymers, and fluoropolymers.

In a preferred embodiment, the article is a safety glass laminatewherein the additional layer is a glass sheet and the interlayer islaminated to the glass sheet. Preferably the interlayer is self-adheredto the glass sheets. Preferably the safety glass laminate comprises twosheets of glass and the interlayer is laminated between the glasssheets. Preferably the interlayer is self-adhered to the two glasssheets. Preferably the interlayer has a thickness of about 10 to about250 mils (about 0.25 to about 6.35 mm).

In another preferred embodiment, the article is a solar cellpre-laminate assembly and comprises a solar cell component comprisingone or a plurality of solar cells. The solar cell pre-laminate assemblypreferably further comprises a second polymeric layer that is positionednext to the solar cell component on the opposite side from the polymericfilm or sheet, wherein the second polymeric layer comprises a polymericcomposition selected from the group consisting of poly(vinyl acetal),ethylene vinyl acetate, polyurethane, polyvinylchloride, polyethylenes,polyolefin block elastomers, ethylene acrylate ester copolymers,copolymer of alpha olefin and alpha,beta-ethylenically unsaturatedcarboxylic acid and ionomers thereof, silicone elastomers and epoxyresins. The solar cell pre-laminate assembly preferably contains anincident layer that is formed of a transparent material (preferablyglass or a plastic film or sheet, most preferably glass) and serves asan outer layer at the light-receiving side of the assembly. The solarcell pre-laminate assembly preferably comprises a backing layer thatserves as an outer layer at the back side of the assembly, wherein thebacking layer preferably is formed of glass, plastic films or sheets, ormetal films or sheets. Preferably, the interlayer has a thickness ofabout 0.1 to about 20 mils (about 0.003 to about 0.5 mm).

In one preferred embodiment, the solar cell pre-laminate assemblyconsists essentially of, from top to bottom, (i) an incident layerformed of a transparent material, which is positioned next to, (ii) afront encapsulant layer that is positioned next to, (iii) a solar cellcomponent comprising one or a plurality of solar cells, which ispositioned next to, (iv) an optional back encapsulant layer that ispositioned next to, (v) a backing layer, wherein at least one of theencapsulant layers is formed of the polymeric film or sheet.

The invention is further directed to an article which is a solar cellprepared by the steps comprising (a) providing interlayer formed of thepolymeric film or sheet, (b) providing a solar cell component comprisingone or a plurality of solar cells; and (c) encapsulating the solar cellcomponent in a matrix comprising the ionomeric composition.

The invention is also directed to a process of manufacturing an article,wherein the article is a solar cell module, the process comprising: (i)providing a solar cell pre-laminate assembly, and (ii) laminating thepre-laminate assembly to form the solar cell module. Preferably the stepof lamination is conducted by subjecting the assembly to heat and,optionally, vacuum.

The invention is also directed to an improved polymeric compositioncomprising an ionomeric composition and an additive, wherein (i) theionomeric composition comprises a copolymer of an alpha olefin and about1 to about 30 wt % of an alpha,beta-ethylenically unsaturated carboxylicacid having 3 to 8 carbons, based on the total weight of the ionomericcopolymer, wherein the carboxylic acid is neutralized to a level of 1 to100 mol %, with one or more metal ions, based on the total number ofmoles of carboxylate groups in the ionomeric copolymer, (ii) theionomeric copolymer has a Melt Index of about 20 to about 300 g/10 minand (iii) the additive is selected from the group consisting of silanecoupling agent, organic peroxide, and combinations thereof. Theinvention is also directed to shaped articles comprising this polymericcomposition. Preferably the shaped article is a polymeric film or sheet.Preferably the film or sheet is a multilayer film or sheet comprisingone surface layer formed of the polymeric composition. Preferably themultilayer film or sheet comprises two surface layers with both beingformed of the polymeric composition. One preferred embodiment is a solarcell or solar cell pre-laminate.

DETAILED DESCRIPTION OF THE INVENTION

All publications, patent applications, patents, and other documentsmentioned herein are incorporated by reference in their entirety. Unlessotherwise defined, all technical and scientific terms used herein havethe same meaning as commonly understood by one of ordinary skill in theart to which this invention belongs. In case of conflict, the presentspecification, including definitions, will control.

Although methods and materials similar or equivalent to those describedherein can be used in the practice or testing of the invention, suitablemethods and materials are described herein.

Unless stated otherwise, all percentages, parts, ratios, etc., are byweight.

When an amount, concentration, or other value or parameter is given aseither a range, preferred range or a list of upper preferable values andlower preferable values, this is to be understood as specificallydisclosing all ranges formed from any pair of any upper range limit orpreferred value and any lower range limit or preferred value, regardlessof whether ranges are separately disclosed. Where a range of numericalvalues is recited herein, unless otherwise stated, the range is intendedto include the endpoints thereof, and all integers and fractions withinthe range. It is not intended that the scope of the invention be limitedto the specific values recited when defining a range.

When the term “about” is used in describing a value or an end-point of arange, the disclosure should be understood to include the specific valueor end-point referred to.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “containing,” “characterized by,” “has,” “having” or anyother variation thereof, are intended to cover a non-exclusiveinclusion. For example, a process, method, article, or apparatus thatcomprises a list of elements is not necessarily limited to only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus. Further, unlessexpressly stated to the contrary, “or” refers to an inclusive or and notto an exclusive or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or notpresent), A is false (or not present) and B is true (or present), andboth A and B are true (or present).

The transitional phrase “consisting of” excludes any element, step, oringredient not specified in the claim, closing the claim to theinclusion of materials other than those recited except for impuritiesordinarily associated therewith. When the phrase “consists of” appearsin a clause of the body of a claim, rather than immediately followingthe preamble, it limits only the element set forth in that clause; otherelements are not excluded from the claim as a whole.

The transitional phrase “consisting essentially of” limits the scope ofa claim to the specified materials or steps and those that do notmaterially affect the basic and novel characteristic(s) of the claimedinvention. “A ‘consisting essentially of’ claim occupies a middle groundbetween closed claims that are written in a ‘consisting of’ format andfully open claims that are drafted in a ‘comprising’ format.”

Where applicants have defined an invention or a portion thereof with anopen-ended term such as “comprising,” it should be readily understoodthat (unless otherwise stated) the description should be interpreted toalso describe such an invention using the terms “consisting essentiallyof” or “consisting of.”

Use of “a” or “an” are employed to describe elements and components ofthe invention. This is done merely for convenience and to give a generalsense of the invention. This description should be read to include oneor at least one and the singular also includes the plural unless it isobvious that it is meant otherwise.

In describing certain polymers it should be understood that sometimesapplicants are referring to the polymers by the monomers used to makethem, the amounts of the monomers used to make them, or by the monomerresidues incorporated within them. While such a description may notinclude the specific nomenclature used to describe the final polymer ormay not contain product-by-process terminology, any such reference tomonomers, monomer residues, repeat units, and amounts should beinterpreted to mean that the polymer is made from those monomers or thatamount of the monomers, and the corresponding polymers and compositionsthereof. In this regard, a reference to a copolymer containing residuesof a monomer is referring to the fact that the copolymer contains repeatunits from that monomer. When applicants refer to a copolymer containinga percentage of a monomer, it should be understood that this referenceis to the copolymer containing repeat units from that monomer.

In describing and/or claiming this invention, the term “copolymer” isused to refer to polymers containing two or more monomers.

The terms “finite amount” and “finite value” are used to refer to anamount that is greater than zero.

The term “acid copolymer” is used to refer to a resin compositioncomprised of copolymerized residues of an alpha olefin and copolymerizedresidues of an alpha, beta-ethylenically unsaturated carboxylic acidhaving 3 to 8 carbons. The term “ionomer” is used herein to refer to aresin composition derived from a partially or fully neutralized “acidcopolymer”.

High Melt Flow Ionomeric Compositions

The invention is related to certain high melt flow ionomericcompositions that are useful in forming safety interlayer sheets orsolar cell encapsulant films or sheets. Specifically, the high melt flowionomeric composition is comprised of an ionomer copolymer having a MIof about 20 to about 300 g/10 min, as measured by ASTM D1238 at 190° C.and a 2160 g load. (A similar ISO test is ISO 1133.)

Ionomeric Copolymers:

The high melt flow ionomeric copolymer is derived from certain parentacid copolymer comprising a finite amount of an alpha olefin and about 1to about 30 wt % of an alpha,beta-ethylenically unsaturated carboxylicacid having 3 to 8 carbons, based on the total weight of the copolymer.Preferably, the parent acid copolymer comprises about 10 to about 25 wt%, or more preferably, about 15 to about 23 wt %, or yet morepreferably, about 18 to about 23 wt %, of the alpha,beta-ethylenicallyunsaturated carboxylic acid, based on the total weight of the copolymer.

The alpha olefin comonomers typically incorporate from 2 to 10 carbonatoms. Preferable alpha olefins include, but are not limited to,ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene,3-methyl-1-butene, 4-methyl-1-pentene, and the like and mixturesthereof. More preferably, the alpha olefin is ethylene. Thealpha,beta-ethylenically unsaturated carboxylic acid comonomers mayinclude acrylic acid, methacrylic acid, itaconic acid, maleic acid,maleic anhydride, fumaric acid, monomethyl maleic acid, and mixturesthereof. Preferable alpha,beta-ethylenically unsaturated carboxylic acidcomonomers include acrylic acid, methacrylic acid and mixtures thereof.

The parent acid copolymers may be polymerized as disclosed in U.S. Pat.No. 3,404,134; U.S. Pat. No. 5,028,674; U.S. Pat. No. 6,500,888; andU.S. Pat. No. 6,518,365.

To produce the high melt flow ionomeric copolymers, the parent acidcopolymers are neutralized from about 1% to about 100%, or preferably,from about 1% to about 50%, or more preferably, from about 2% to about40%, or yet more preferably, from about 2% to about 20%, with metallicions, based on the total carboxylic acid content. The metallic ions maybe monovalent, divalent, trivalent, multivalent, or mixtures therefrom.Useful monovalent metallic ions include, but are not limited to, sodium,potassium, lithium, silver, mercury, copper, and the like and mixturesthereof. Useful divalent metallic ions include, but are not limited to,beryllium, magnesium, calcium, strontium, barium, copper, cadmium,mercury, tin, lead, iron, cobalt, nickel, zinc, and the like andmixtures therefrom. Useful trivalent metallic ions include, but are notlimited to, aluminum, scandium, iron, yttrium, and the like and mixturestherefrom. Useful multivalent metallic ions include, but are not limitedto, titanium, zirconium, hafnium, vanadium, tantalum, tungsten,chromium, cerium, iron, and the like and mixtures therefrom. It is notedthat when the metallic ion is multivalent, complexing agents, such asstearate, oleate, salicylate, and phenolate radicals are included, asdisclosed within U.S. Pat. No. 3,404,134. The metallic ions arepreferably monovalent or divalent metallic ions. More preferably, themetallic ions are selected from the group consisting of sodium, lithium,magnesium, zinc, and mixtures therefrom. Yet more preferably, themetallic ions are selected from the group consisting of sodium, zinc,and mixtures therefrom. The parent acid copolymers of the invention maybe neutralized as disclosed in U.S. Pat. No. 3,404,134.

The high melt flow ionomeric copolymers have a MI of about 20 to about300 g/10 min. Preferably, the ionomeric copolymers have a MI of about 30to about 200 g/10 min. In general, to achieve the desirable high meltflow rates of the ionomeric copolymers, the parent acid copolymersshould have a MI of about 50 to about 600 g/10 min, or preferably, about50 to about 400 g/10 min, or more preferably, about 50 to about 200 g/10min.

Such a high melt flow rate provides the ionomeric films or sheetsderived therefrom with reduced lamination temperatures, or shorter cycletime, or both, when they are used in safety laminates or solar celllaminates. Moreover, when laminated under the lamination temperatures,films or sheets derived from such high melt flow ionomeric compositionspossess higher adhesion strength than those derived from ionomericcompositions with relatively lower melt flow rates.

The high melt flow ionomeric copolymers may optionally contain otherunsaturated comonomers. Specific examples of preferable otherunsaturated comonomers include, but are not limited to, methyl acrylate,methyl methacrylate, ethyl acrylate, ethyl methacrylate, isopropylacrylate, isopropyl methacrylate, butyl acrylate, butyl methacrylate andmixtures thereof. In general, the ionomeric copolymers may incorporate 0to about 50 wt %, or preferably, 0 to about 30 wt %, or more preferably,0 to about 20 wt %, of the other unsaturated comonomer(s), based on thetotal weight of the copolymer.

Additives:

The high melt flow ionomeric composition may further comprise one ormore additives.

In one particular embodiment, the ionomeric composition furthercomprises one or more silane coupling agents to further enhance theadhesion strength of the films or sheets derived therefrom.

Exemplary silane coupling agents that are useful in the inventioninclude, but are not limited to, gamma-chloropropylmethoxysilane,vinyltrimethoxysilane, vinyltriethoxysilane,vinyltris(beta-methoxyethoxy)silane,gamma-vinylbenzylpropyltrimethoxysilane,N-beta-(N-vinylbenzylaminoethyl)-gamma-aminopropyltrimethoxysilane,gamma-methacryloxypropyltrimethoxysilane, vinyltriacetoxysilane,gamma-glycidoxypropyltrimethoxysilane,gamma-glycidoxypropyltriethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, vinyltrichlorosilane,gamma-mercaptopropylmethoxysilane, gamma-aminopropyltriethoxysilane,N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane, and the like andmixtures thereof. The silane coupling agents are preferably incorporatedin the ionomeric compositions at a level of about 0.01 to about 5 wt %,or more preferably, about 0.05 to about 1 wt %, based on the totalweight of the composition.

It is noted that the silane coupling agents can reduce the melt flowrate of the ionomeric compositions to which they are incorporated.Therefore, with a set level of silane, the high melt flow ionomericcompositions can maintain a certain level of viscosity than the priorart lower melt flow ionomeric compositions.

In another embodiment of the invention, the ionomeric compositions mayfurther comprise additives which effectively reduce the melt flow of theresin, to the limit of thermosetting the films or sheets duringlamination. The use of such additives will enhance the upper end-usetemperature and reduce creep of the laminate interlayer sheets or solarcell encapsulant films or sheets derived therefrom. Typically, theend-use temperature may be enhanced up to about 20 to about 70° C. Inaddition, safety laminates and solar cell laminates produced from suchmaterials will be fire resistant. Specifically, by thermosetting theionomeric resins during lamination, the resins will have a reducedtendency to melt and flow out of the laminate, which in turn, may serveas additional fuel for a fire.

Typically, the effective melt flow reducing additives are organicperoxides, such as 2,5-dimethylhexane-2,5-dihydroperoxide,2,5-dimethyl-2,5-di(tert-betylperoxy)hexane-3, di-tert-butyl peroxide,tert-butylcumyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane,dicumyl peroxide, alpha,alpha′-bis(tert-butyl-peroxyisopropyl)benzene,n-butyl-4,4-bis(tert-butylperoxy)valerate,2,2-bis(tert-butylperoxy)butane, 1,1-bis(tert-butyl-peroxy)cyclohexane,1,1-bis(tert-butylperoxy)-3,3,5-trimethyl-cyclohexane, tert-butylperoxybenzoate, benzoyl peroxide, and the like and mixtures combinationsthereof. Preferably the organic peroxides decompose at a temperature ofabout 100° C. or higher to generate radicals. More preferably, theorganic peroxides have a decomposition temperature which affords a halflife of 10 hours at about 70° C. or higher to provide improved stabilityfor blending operations.

Moreover, the temperature gap between the ionomer compositioncompounding temperature and the organic peroxide decompositiontemperature is critical to avoid premature crosslinking during thecompounding and film and sheet formation processes. In an extrusionprocess (which is the preferred process for manufacturing the high meltflow ionomeric films or sheets), the high melt flow ionomericcompositions require desirable reduced extrusion temperatures whencompared to the otherwise lower melt flow ionomeric compositions andtherefore effectively preventing premature crosslinking during extrusioncompounding, film or sheet formation.

The organic peroxides are added at a level of about 0.01 to about 10 wt%, or preferably, about 0.5 to about 3 wt %, based on the total weightof the composition.

If desired, initiators, such as dibutyltin dilaurate, may also becontained in the ionomeric composition at a level of about 0.01 to about0.05 wt %, based on the total weight of the composition. In addition, ifdesired, inhibitors, such as hydroquinone, hydroquinone monomethylether, p-benzoquinone, and methylhydroquinone, may be added for thepurpose of enhancing control to the reaction and stability. Typically,the inhibitors would be added at a level of less than about 5 wt %,based on the total weight of the composition.

In yet another embodiment, the high melt flow ionomeric composition mayfurther comprise any other suitable additive(s) known within the art.Such additives may include, but are not limited to, plasticizers,processing aides, flow enhancing additives, lubricants, pigments, dyes,flame retardants, impact modifiers, nucleating agents, antiblockingagents (e.g., silica), thermal stabilizers, UV absorbers, UVstabilizers, dispersants, surfactants, chelating agents, couplingagents, adhesives, primers, reinforcement additives (e.g., glass fiber),fillers, and the like. Generally, when used in solar cell encapsulantfilms or sheets, the additives that may reduce the optical clarity ofthe compositions, such as reinforcement additives and fillers, arereserved for those films or sheets used as the back encapsulant layers.

Thermal stabilizers can be used and have been widely disclosed withinthe art. Any known thermal stabilizer may find utility within theinvention. Preferable general classes of thermal stabilizers include,but are not limited to, phenolic antioxidants, alkylated monophenols,alkylthiomethylphenols, hydroquinones, alkylated hydroquinones,tocopherols, hydroxylated thiodiphenyl ethers, alkylidenebisphenols, O-,N- and S-benzyl compounds, hydroxybenzylated malonates, aromatichydroxybenzyl compounds, triazine compounds, aminic antioxidants, arylamines, diaryl amines, polyaryl amines, acylaminophenols, oxamides,metal deactivators, phosphites, phosphonites, benzylphosphonates,ascorbic acid (vitamin C), compounds that destroy peroxide,hydroxylamines, nitrones, thiosynergists, benzofuranones, indolinones,and the like and mixtures thereof. The high melt flow ionomericcompositions may contain any effective amount of thermal stabilizers.Use of a thermal stabilizer is optional and in some instances is notpreferred. When used, the high melt flow ionomeric compositions containat least about 0.05 wt %, and up to about 10 wt %, more preferably up toabout 5 wt %, and most preferably up to about 1 wt %, of thermalstabilizers, based on the total weight of the composition.

UV absorbers can be used and have also been widely disclosed within theart. Any known UV absorber may find utility within the invention.Preferable general classes of UV absorbers include, but are not limitedto, benzotriazoles, hydroxybenzophenones, hydroxyphenyl triazines,esters of substituted and unsubstituted benzoic acids, and the like andmixtures thereof. The high melt flow ionomeric compositions may containany effective amount of UV absorbers. Use of an UV absorber is optionaland in some instances is not preferred. When used, the high melt flowionomeric compositions contain at least about 0.05 wt %, and up about 10wt %, more preferably up to about 5 wt %, and most preferably up toabout 1 wt %, of UV absorbers, based on the total weight of thecomposition.

Hindered amine light stabilizers (HALS) can be used and have also beenwidely disclosed within the art. Generally, hindered amine lightstabilizers are disclosed to be secondary, tertiary, acetylated,N-hydrocarbyloxy substituted, hydroxy substituted N-hydrocarbyloxysubstituted, or other substituted cyclic amines which furtherincorporate steric hindrance, generally derived from aliphaticsubstitution on the carbon atoms adjacent to the amine function. Thehigh melt flow ionomeric compositions may contain any effective amountof hindered amine light stabilizers. Use of hindered amine lightstabilizers is optional and in some instances is not preferred. Whenused, the high melt flow ionomeric compositions contain at least about0.05 wt %, and up to about 10 wt %, more preferably up to about 5 wt %,and most preferably, up to about 1 wt %, of hindered amine lightstabilizers, based on the total weight of the composition.

High Melt Flow Ionomeric Films or Sheets

The invention further provides shaped articles, such as, films or sheetscomprising the high melt flow ionomeric compositions. These high meltflow ionomeric films and sheets may be produced by any suitable process.For example, the films and sheets may be formed through dipcoating,solution casting, compression molding, injection molding, meltextrusions, melt blowing, or any other procedures that are known tothose of skill in the art. Preferably, the high melt flow ionomericfilms and sheets are formed by melt extrusion, which is a particularlypreferred process for formation of “endless” products.

As discussed above, the high melt flow ionomeric films or sheets areuseful in forming the interlayer sheets in safety laminates orencapsulant films or sheets in solar cell laminates. Moreover, the highmelt flow ionomeric films or sheets may take the form of single-layer ormultilayer films or sheets. By single-layer, it is meant that the filmor sheet has only one single layer and that the one single layer is madeof the high melt flow ionomeric composition. By multilayer, it is meantthat the high melt flow ionomeric film or sheet has two or moresub-layers and that at least one of the sub-layers is made of the highmelt flow ionomeric composition. The other sub-layer(s) of themultilayer film or sheet may be made of any suitable polymericcompositions. Preferably, however, the other sub-layer(s) is made ofpolymeric compositions selected from the group consisting of acidcopolymers and ionomers derived therefrom, poly(ethylene vinyl acetate),poly(vinyl acetal) (e.g., poly(vinyl butyral)), polyurethane,polyvinylchloride, polyethylenes (e.g., metallocene-catalyzed linear lowdensity polyethylenes), polyolefin block elastomers, ethylene acrylateester copolymers (e.g., poly(ethylene-co-methyl acrylate) andpoly(ethylene-co-butyl acrylate)), silicone elastomers and epoxy resins.More preferably, the other sub-layers are formed of polymericcompositions selected from the group consisting of acid copolymers andionomers derived therefrom, poly(ethylene vinyl acetate),metallocene-catalyzed linear low density polyethylenes, polyolefin blockelastomers, and ethylene acrylate ester copolymers. Moreover, to provideadequate adhesion strength, at least one, or preferably, both, of thesurface sub-layers of the multilayer film or sheet are formed of thehigh melt flow ionomeric compositions. In one preferred embodiment,multilayer films and sheets with high flow ionomeric copolymer surfacesand low flow core layers provide the desirable low laminationtemperatures and high adhesion of the invention.

The films or sheets of the invention preferably have a total thicknessof about 0.1 mil (0.003 mm) to about 250 mils (6.35 mm). When used as asafety laminate interlayer sheet, the high melt flow ionomeric sheetpreferably has a total thickness of about 10 mils (0.25 mm) to about 250mils (6.35 mm), or more preferably, about 15 mils (0.38 mm) to about 90mils (2.28 mm), or yet more preferably, about 30 mils (0.76 mm) to about60 mils (1.52 mm). Also in accordance to the invention, for use as asolar cell encapsulant the sheet or film preferably has a thickness ofabout 0.1 mil (0.003 mm) to about 20 mils (0.51 mm). That is, when usedin a flexible solar cell laminate as a solar cell encapsulant film, thehigh melt flow ionomeric film preferably has a total thickness of about0.1 mil (0.003 mm) to about 10 mils (0.25 mm), or more preferably, about1 mil (0.03 mm) to about 5 mils (0.13 mm), while when used in a rigidsolar cell laminate as a solar cell encapsulant sheet, the high meltflow ionomeric sheet preferably has a total thickness of about 10 mils(0.25 mm) to about 20 mils (0.51 mm). The thickness of the individualsub-layers that make up the total multilayer ionomeric film or sheet isnot critical and may be independently varied depending on the particularapplication. Preferably, however, the surface layers of a multilayerfilm or sheet should have a thickness of about 1 mil (0.03 mm) to about5 mils (0.13 mm).

The high melt flow ionomeric films or sheets may have smooth or roughsurfaces on one or both sides. Preferably, the high melt flow films orsheets have rough surfaces to facilitate the de-airing of the laminatesthrough the laminate process. Providing channels for the escape of airand removing air during lamination is a known method for obtaininglaminates having acceptable appearance. Rough surfaces can be effectedby mechanically embossing or by melt fracture during extrusion of theinterlayer sheet or encapsulant film or sheet followed by quenching sothat the roughness is retained during handling. The surface pattern canbe applied to the high melt flow ionomeric film or sheet through commonart processes. For example, the as extruded film or sheet may be passedover a specially prepared surface of a die roll positioned in closeproximity to the exit of the die which imparts the desired surfacecharacteristics to one side of the molten polymer. Thus, when thesurface of such roll has minute peaks and valleys, film or sheet formedof polymer cast thereon will have a rough surface on the side whichcontacts the roll which generally conforms respectively to the valleysand peaks of the roll surface. Such die rolls are disclosed in, e.g.,U.S. Pat. No. 4,035,549.

If desired, one or both surfaces of the high melt flow ionomeric film orsheet may be treated to enhance the adhesion to other laminate layers.This treatment may take any form known within the art, includingadhesives, primers, such as silanes, flame treatments (see, e.g., U.S.Pat. No. 2,632,921; U.S. Pat. No. 2,648,097; U.S. Pat. No. 2,683,894;and U.S. Pat. No. 2,704,382), plasma treatments (see e.g., U.S. Pat. No.4,732,814), electron beam treatments, oxidation treatments, coronadischarge treatments, chemical treatments, chromic acid treatments, hotair treatments, ozone treatments, ultraviolet light treatments, sandblast treatments, solvent treatments, and the like and combinationsthereof. For example, a thin layer of carbon may be deposited on one orboth surfaces of the film or sheet through vacuum sputtering asdisclosed in U.S. Pat. No. 4,865,711. U.S. Pat. No. 5,415,942, on theother hand, discloses a hydroxy-acrylic hydrosol primer coating that mayserve as an adhesion-promoting primer for poly(ethylene terephthalate)films.

The adhesive layer preferably can take the form of a monolayer of anadhesive primer or of a coating. The adhesive/primer coating may be lessthan about 1 mil (0.03 mm), or preferably, less than about 0.5 mil(0.013 mm), or more preferably, less than about 0.1 mil (0.003 mm)thick. The adhesives may be any adhesive or primer known within the art.Preferably, the adhesives or primers are silane coupling agents orpoly(vinyl amine) or poly(allyl amine). The poly(allyl amine)-basedprimers and their application to poly(ethylene terephthalate) polymericfilms are disclosed within U.S. Pat. No. 5,411,845; U.S. Pat. No.5,770,312; U.S. Pat. No. 5,690,994; and U.S. Pat. No. 5,698,329.

Safety Laminates

The invention further provides safety laminates comprising a polymericinterlayer sheet formed of the high melt flow ionomeric composition.Specifically, the safety laminate comprises at least one rigid sheetlayer and at least one layer of the high melt flow ionomeric sheet as aninterlayer sheet.

As discussed above, at the lamination temperatures used herein, the highmelt flow ionomeric interlayer sheets typically possess higher adhesionstrength than those sheets derived from otherwise low melt flowionomers, and therefore providing the safety laminate structures withimproved shock resistance.

The rigid sheets may be glass or rigid plastic sheets, such as,polycarbonate, acrylics, polyacrylate, cyclic polyolefins (e.g.,ethylene norbornene polymers), metallocene-catalyzed polystyrene,polyamides, polyesters, fluoropolymers and the like and combinationsthereof. Metal sheets (such as, aluminum, steel or galvanized steel) orceramic plates may be substituted for the rigid polymeric sheet orglass.

The term “glass” is meant to include not only window glass, plate glass,silicate glass, sheet glass, low iron glass, tempered glass, temperedCeO-free glass, and float glass, but also to include colored glass,specialty glass (such as those include ingredients to control, e.g.,solar heating), coated glass (such as those sputtered with metals (e.g.,silver or indium tin oxide) for solar control purposes), E-glass,Toroglass, Solex® glass (Solutia). Such specialty glasses are disclosedin, e.g., U.S. Pat. No. 4,615,989; U.S. Pat. No. 5,173,212; U.S. Pat.No. 5,264,286; U.S. Pat. No. 6,150,028; U.S. Pat. No. 6,340,646; U.S.Pat. No. 6,461,736; and U.S. Pat. No. 6,468,934. It is understood,however, that the type of glass to be selected for a particular laminatedepends on the intended use.

One preferred embodiment of the invention is a safety laminatecomprising at least one layer of glass, and at least one layer of thehigh melt flow ionomeric sheet. Preferably, the high melt flow ionomericsheet is self-adhered to the glass. As used herein, when the polymericsheet is said to be “self-adhered” to the glass, it is meant that thereis no intermediate layer such as a primer or thin adhesive layer betweenthe glass and the polymeric layer, nor has the surface of the glass orpolymeric layer been specially treated. A more preferred embodiment ofthe invention is a laminate comprising two layers of glass and at leastone layer of the high melt flow ionomeric sheets bonded in between.Preferably, the high melt flow ionomeric sheet is self-adhered to one orboth of the glass layers.

The safety laminate of the invention may further comprise other optionalinterlayer sheets and/or film layers. The other optional interlayersheets may be formed of any suitable materials, such as, acid copolymersand ionomers derived therefrom, poly(ethylene vinyl acetate), poly(vinylacetal) (e.g., poly(vinyl butyral)), polyurethane, polyvinylchloride,polyethylenes (e.g., metallocene-catalyzed linear low densitypolyethylenes), polyolefin block elastomers, ethylene acrylate estercopolymers (e.g., poly(ethylene-co-methyl acrylate) andpoly(ethylene-co-butyl acrylate)), silicone elastomers and epoxy resins.In one preferred embodiment, the other interlayer is a second polymericfilm or sheet comprising an ionomeric composition. The thickness of theother optional interlayer sheet(s) is not critical and may beindependently varied depending on the particular application. The valuesprovided above for the acid copolymer layer are preferred in manyinstances.

The film layers used in the safety laminates may be metal, such asaluminum foil, or polymeric. Preferable polymeric film materialsinclude, but are not limited to, polyesters (e.g., poly(ethyleneterephthalate) (PET)), poly(ethylene naphthalate), polycarbonate,polyolefins (e.g., polypropylene, polyethylene, and cyclic polyloefins),norbornene polymers, polystyrene (including syndiotactic polystyrene),styrene-acrylate copolymers, acrylonitrile-styrene copolymers,polysulfones (e.g., polyethersulfone, polysulfone, etc.), nylons,poly(urethanes), acrylics, cellulose acetates (e.g., cellulose acetate,cellulose triacetates, etc.), cellophane, vinyl chloride polymers (e.g.,polyvinylidene chloride, vinylidene chloride copolymers, etc.),fluoropolymers (e.g., polyvinyl fluoride, polyvinylidene fluoride,polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymers, etc.)and the like. More preferably, the polymeric film is a biaxiallyoriented poly(ethylene terephthalate) film.

The thickness of the polymeric film is not critical and may be varieddepending on the particular application. In general, however, thethickness of the polymeric film may range from about 0.1 mils (0.003 mm)to about 10 mils (0.26 mm), or preferably, from about 1 mil (0.025 mm)to about 7 mils (0.18 mm).

In addition, the polymeric films are sufficiently stress-relieved andshrink-stable under the coating and lamination processes. Preferably,the polymeric films are heat stabilized to provide low shrinkagecharacteristics when subjected to elevated temperatures (i.e. less than2% shrinkage in both directions after 30 min at 150° C.).

The films may also be coated if desired. For example, the films may becoated with organic infrared absorbers and sputtered metal layers, suchas silver, coatings and the like. Metal coated polymeric films aredisclosed in, e.g., U.S. Pat. No. 3,718,535; U.S. Pat. No. 3,816,201;U.S. Pat. No. 4,465,736; U.S. Pat. No. 4,450,201; U.S. Pat. No.4,799,745; U.S. Pat. No. 4,846,949; U.S. Pat. No. 4,954,383; U.S. Pat.No. 4,973,511; U.S. Pat. No. 5,071,206; U.S. Pat. No. 5,306,547; U.S.Pat. No. 6,049,419; U.S. Pat. No. 6,104,530; U.S. Pat. No. 6,204,480;U.S. Pat. No. 6,255,031; and U.S. Pat. No. 6,565,982. For example, thecoating may function as oxygen and moisture barrier coatings, such asthe metal oxide coating disclosed within U.S. Pat. No. 6,521,825; U.S.Pat. No. 6,818,819; and EP 1 182 710.

If desired, one or both surfaces of laminate layers, such as theionomeric interlayer sheet(s), the optional other interlayer sheet(s) orfilm layer(s), or the rigid sheet(s), may be treated to enhance theiradhesion strength, as described above.

The safety laminate of the invention may take any form known within theart. Preferable specific glass laminate constructions include, forexample, wherein “ION” means the preferable high melt flow ionomercomprising interlayer sheet, as described above,

glass/ION;

glass/ION/film;

glass/ION/glass;

glass/ION/film/ION/glass;

glass/ION/film/ION/film;

and the like.

The safety laminates of the invention may be produced by any of thelamination process that are described below in detail, or by otherprocesses.

Solar Cell Pre-Laminate Assemblies and Solar Cell Laminates

The invention further provides a solar cell pre-laminate assembly whichcomprises a solar cell component formed of one or a plurality solarcells and at least one layer of the high melt flow ionomeric film orsheet that is described above.

Solar cells are commonly available on an ever increasing variety as thetechnology evolves and is optimized. Within the invention, a “solarcell” is meant to include any article which can convert light intoelectrical energy. Typical art examples of the various forms of solarcells include, for example, single crystal silicon solar cells,polycrystal silicon solar cells, microcrystal silicon solar cells,amorphous silicon based solar cells, copper indium selenide solar cells,compound semiconductor solar cells, dye sensitized solar cells, and thelike. The most common types of solar cells include multi-crystallinesolar cells, thin film solar cells, compound semiconductor solar cellsand amorphous silicon solar cells due to relatively low costmanufacturing ease for large scale solar cells.

Thin film solar cells are typically produced by depositing several thinfilm layers onto a substrate, such as glass or a flexible film, with thelayers being patterned so as to form a plurality of individual cellswhich are electrically interconnected to produce a suitable voltageoutput. Depending on the sequence in which the multi-layer deposition iscarried out, the substrate may serve as the rear surface or as a frontwindow for the solar cell module. By way of example, thin film solarcells are disclosed in U.S. Pat. No. 5,512,107; U.S. Pat. No. 5,948,176;U.S. Pat. No. 5,994,163; U.S. Pat. No. 6,040,521; U.S. Pat. No.6,137,048; and U.S. Pat. No. 6,258,620. Examples of thin film solar cellmodules are those that comprise cadmium telluride or CIGS,(Cu(In—Ga)(SeS)2), thin film cells.

In one particular embodiment, the solar cell pre-laminate assemblycomprises one layer of the high melt flow ionomeric film or sheet, whichis positioned next to the solar cell component and serves as one of theencapsulant layers, or preferably, the high melt flow ionomeric film orsheet is positioned next to the solar cell component at thelight-receiving side and serves as the front encapsulant layer.

In accordance with the invention, besides the at least one high meltflow ionomeric film or sheet, the solar cell pre-laminate assembly mayoptionally further comprise encapsulant layers formed of other polymericmaterials, such as, acid copolymers and ionomers derived therefrom,poly(ethylene vinyl acetate), poly(vinyl acetal) (e.g., poly(vinylbutyral), including acoustic grades of poly(vinyl butyral)),polyurethane, poly vinyl chloride, polyethylenes (e.g., linear lowdensity metallocene-catalyzed polyethylenes), polyolefin blockelastomers, ethylene acrylate ester copolymers (e.g.,poly(ethylene-co-methyl acrylate) and poly(ethylene-co-butyl acrylate)),silicone elastomers and epoxy resins.

In a further embodiment, the solar cell pre-laminate assembly comprisestwo layers of the high melt flow ionomeric film or sheet, wherein eachof the two high melt flow ionomeric films or sheets are laminated toeach of the two sides of the solar cell component and serve as the frontand back encapsulant layers.

The thickness of the individual encapsulant layers other than the highmelt flow ionomeric film(s) or sheet(s) is not critical and may beindependently varied depending on the particular application.Preferably, the thickness of each of these encapsulant layers mayindependently range from about 1 mil (0.026 mm) to about 120 mils (3.00mm), or more preferably, from about 1 mil to about 40 mils (1.02 mm), ormost preferably, from about 1 mil to about 20 mils (0.51 mm). Inaddition, all the encapsulant layer(s) comprised in the solar cellpre-laminate assemblies, may have smooth or rough surfaces. Preferably,however, the encapsulant layer(s) have rough surfaces to facilitate thede-airing of the laminates through the lamination process.

In yet a further embodiment, the solar cell pre-laminate assembly mayfurther comprise an incident layer and/or a backing layer serving as theouter layers of the assembly at the light-receiving side and the backside, respectively.

The outer layers of the solar cell pre-laminate assemblies, i.e., theincident layers and the backing layer, may be derived from any suitablesheets or films. Suitable sheets may be glass or plastic sheets, suchas, polycarbonate, acrylics, polyacrylate, cyclic polyolefins (e.g.,ethylene norbornene polymers), metallocene-catalyzed polystyrene,polyamides, polyesters, fluoropolymers and the like and combinationsthereof. In addition, metal sheets, such as aluminum, steel, galvanizedsteel, or ceramic plates may be utilized in forming the back-sheet.

Suitable film layers may be polymeric. Preferred polymers used to formthe polymeric films, include but are not limited to, polyesters (e.g.,poly(ethylene terephthalate)), poly(ethylene naphthalate),polycarbonate, polyolefins (e.g., polypropylene, polyethylene, andcyclic polyloefins), norbornene polymers, polystyrene (includingsyndiotactic polystyrene), styrene-acrylate copolymers,acrylonitrile-styrene copolymers, polysulfones (e.g., polyethersulfone,polysulfone, etc.), nylons, poly(urethanes), acrylics, celluloseacetates (e.g., cellulose acetate, cellulose triacetates, etc.),cellophane, vinyl chloride polymers (e.g., polyvinylidene chloride,vinylidene chloride copolymers, etc.), fluoropolymers (e.g., polyvinylfluoride, polyvinylidene fluoride, polytetrafluoroethylene,ethylene-tetrafluoroethylene copolymers, etc.) and the like. Mostpreferably, the polymeric film is biaxially oriented polyester film(preferably poly(ethylene terephthalate) film) or a fluoropolymer film(e.g., Tedlar®, Tefzel®, and Teflon® films, from E. I. du Pont deNemours and Company, Wilmington, Del.).Fluoropolymer-polyester-fluoropolymer (“TPT”) films are also preferredfor some applications. Metal films, such as aluminum foil may also beused herein as the back-sheet.

The solar cell pre-laminate assembly of the invention, may optionallyfurther comprise other functional film or sheet layers (e.g., dielectriclayers or barrier layers) embedded within the assembly. Such functionallayers may be derived from any of the above mentioned polymeric films orthose that are coated with additional functional coatings. For example,poly(ethylene terephthalate) films coated with a metal oxide coating,such as those disclosed within U.S. Pat. No. 6,521,825; U.S. Pat. No.6,818,819; and EP 1 182 710, may function as oxygen and moisture barrierlayers in the laminates.

If desired, a layer of non-woven glass fiber (scrim) may also beincluded in the solar cell laminates to facilitate de-airing during thelamination process or to serve as reinforcement for the encapsulantlayer(s). The use of such scrim layers within solar cell laminates isdisclosed within, e.g., U.S. Pat. No. 5,583,057; U.S. Pat. No.6,075,202; U.S. Pat. No. 6,204,443; U.S. Pat. No. 6,320,115; U.S. Pat.No. 6,323,416; and EP 0 769 818.

In addition, it is understood that all the film or sheet layerspositioned to the light-receiving side of the solar cell layer are madeof transparent material to allow efficient transmission of sunlight intothe solar cell component. In some instances, a special film or sheet maybe included to serve both the function of an encapsulant layer and anouter layer. It is also conceivable that any of the film or sheet layersincluded in the assembly may be in the form of a pre-formed single-layeror multi-layer film or sheet.

If desired, one or both surfaces of the laminate layers of the solarcell pre-laminate assemblies may be treated to enhance the adhesionstrength, as described above.

The solar cell pre-laminate assemblies may take any form known withinthe art. Preferable specific solar cell pre-laminate constructions (top(light incident) side to back side) include, for example, wherein “ION”means the preferable high melt flow ionomeric encapsulant film or sheetof the invention, as described above,

-   -   glass/ION/solar cell/ION/glass;    -   glass/ION/solar cell/ION/fluoropolymer film;    -   fluoropolymer film/ION/solar cell/ION/glass;    -   fluoropolymer film/ION/solar cell/ION/fluoropolymer film;    -   glass/ION/solar cell/ION/polyester film;    -   fluoropolymer film/ION/solar cell/ION/polyester film;    -   glass/ION/solar cell/ION/barrier coated film/ION/glass;    -   fluoropolymer film/ION/barrier coated film/ION/solar        cell/ION/barrier coated film/ION/fluoropolymer film;    -   glass/ION/solar cell/ION/aluminum stock;    -   fluoropolymer film/ION/solar cell/ION/aluminum stock;    -   glass/ION/solar cell/ION/galvanized steel sheet;    -   glass/ION/solar cell/ION/polyester film/ION/aluminum stock;    -   fluoropolymer film/ION/solar cell/ION/polyester        film/ION/aluminum stock;    -   glass/ION/solar cell/ION/polyester film/ION/galvanized steel        sheet;    -   fluoropolymer film/ION/solar cell/ION/polyester        film/ION/galvanized steel sheet;    -   glass/ION/solar cell/acoustic poly(vinyl butyral) encapsulant        layer/glass;    -   glass/ION/solar cell/poly(vinyl butyral) encapsulant        layer/fluoropolymer film,    -   fluoropolymer film/ION/solar cell/acid copolymer encapsulant        layer/Tedlar® film;    -   glass/ION/solar cell/ethylene vinyl acetate encapsulant        layer/polyester film;    -   fluoropolymer film/ION/solar cell/poly(ethylene-co-methyl        acrylate) encapsulant layer/polyester film;    -   glass/poly(ethylene-co-butyl acrylate) encapsulant layer/solar        cell/ION/barrier coated film/poly(ethylene-co-butyl acrylate)        encapsulant layer/glass;        and the like.

The preferred fluoropolymer film in each of the above examples is aTedlar® fluoropolymer film or a fluoropolymer-polyester-fluoropolymertrilayer film. The preferred polyester film in each of the aboveexamples is a poly(ethylene terephthalate) film. The term “glass” isintended to refer to sheets of any of the aforementioned types of glassor glass alternatives.

The invention further provides solar cell laminates produced from thesolar cell pre-laminate assemblies disclosed above. Specifically thesolar cell laminates are formed by subjecting the solar cellpre-laminate assemblies to further lamination process, as provided belowin detail.

Moreover, as discussed above, under the lamination temperature usedherein, the high melt flow ionomeric encapsulant films or sheets possesshigher adhesion strength than those encapsulant films or sheets derivedfrom otherwise low melt flow ionomers, and therefore providing the solarcell laminate structures at the reduced lamination conditions describedherein, and therefore provide solar cell laminate structures with asimplified production process.

Lamination Process

The invention further provides a simplified process for producing thesafety laminates or solar cell laminates. Specifically, as providedabove, the incorporation of the high melt flow ionomeric interlayersheets or high melt flow ionomeric solar cell encapsulant films orsheets requires reduced lamination temperatures, or cycle time, or bothcompared to those used in the process involving low melt flow ionomers.

The lamination process may be an autoclave or non-autoclave process.

In an exemplary process, a glass sheet, a front encapsulant layer, asolar cell component, a back encapsulant layer and a backing layer(e.g., Tedlar® film), and a cover glass sheet are laid up and laminatedtogether under heat and pressure and a vacuum (for example, in the rangeof about 27-28 inches (689-711 mm) Hg) to remove air. Preferably, theglass sheet has been washed and dried. A typical glass type is 90 milthick annealed low iron glass. In an exemplary procedure, thepre-laminate assembly of the invention is placed into a bag capable ofsustaining a vacuum (“a vacuum bag”), drawing the air out of the bagusing a vacuum line or other means of pulling a vacuum on the bag,sealing the bag while maintaining the vacuum, placing the sealed bag inan autoclave at a temperature of about 100° C. to about 180° C., at apressure of about 150 to about 250, preferably about 200 psig (about 15bar), for about 10 to about 50 minutes. Preferably the bag is autoclavedat a temperature of about 100° C. to about 120° C. for about 20 to about45 minutes. More preferably the bag is autoclaved at a temperature ofabout 110° C. to about 120° C. for about 20 to about 40 minutes. Avacuum ring may be substituted for the vacuum bag. One type of vacuumbags is disclosed within U.S. Pat. No. 3,311,517. The high melt flowionomeric films and sheets of the invention provide the desirableadvantage of lower lamination temperatures and/or faster laminationcycle times, depending on the laminator's choice.

Any air trapped within the pre-laminate assembly may be removed througha nip roll process. For example, the pre-laminate assembly may be heatedin an oven at a temperature of about 80° C. to about 120° C., orpreferably, at a temperature of between about 90° C. and about 100° C.,for about 15 to about 60 (preferably about 30) minutes. Thereafter, theheated pre-laminate assembly is passed through a set of nip rolls sothat the air in the void spaces between the solar cell outside layers,the solar cell component, and the encapsulant layers may be squeezedout, and the edge of the assembly sealed. This process may provide thefinal solar cell module or may provide what is referred to as apre-press assembly, depending on the materials of construction and theexact conditions utilized.

The pre-press assembly may then be placed in an air autoclave where thetemperature is raised to about 100° C. to about 160° C., or preferablybetween about 110° C. and about 120° C., and pressure to between about100 psig and about 300 psig, or preferably, about 200 psig (14.3 bar).These conditions are maintained for about 15 minutes to about 1 hour, orpreferably, about 20 to about 50 minutes, after which, the air is cooledwhile no more air is added to the autoclave. After about 10 to about 30(preferably about 20) minutes of cooling, the excess air pressure isvented and the solar cell laminates are removed from the autoclave. Thisshould not be considered limiting. Essentially any lamination processknown within the art may be used herein.

A non-autoclave lamination process has been disclosed, e.g., within U.S.Pat. No. 3,234,062; U.S. Pat. No. 3,852,136; U.S. Pat. No. 4,341,576;U.S. Pat. No. 4,385,951; U.S. Pat. No. 4,398,979; U.S. Pat. No.5,536,347; U.S. Pat. No. 5,853,516; U.S. Pat. No. 6,342,116; U.S. Pat.No. 5,415,909; US 2004-0182493; US 2003-0148114 A1; EP 1 235 683 B1; WO91/01880; and WO 03/057478 A1. Generally, the non-autoclave processincludes heating the pre-laminate assembly or the pre-press assemblyand, optionally, the application of vacuum, pressure or both. Forexample, the pre-press may be successively passed through heating ovensand nip rolls. A commercial example of a photovoltaic lamination processincludes the Icolam vacuum laminating systems of Meier VakuumtechnikGmbH, Bocholt, Germany.

In producing solar cell laminates, if desired, the edges of thelaminates may be sealed to reduce moisture and air intrusion and thepotential degradation effect on the efficiency and lifetime of the solarcell(s) by any means disclosed within the art. Suitable edge sealmaterials include, but are not limited to, butyl rubber, polysulfide,silicone, polyurethane, polypropylene elastomers, polystyreneelastomers, block elastomers, styrene-ethylene-butylene-styrene (SEBS),and the like.

EXAMPLES

The following Examples and are intended to be illustrative of theinvention, and are not intended in any way to limit the scope of theinvention.

Methods

The following methods are used in the Examples presented hereafter.

Melt Index

Melt Index (MI) is measured by ASTM D1238 at 190° C. using a 2160 gload. A similar ISO test is ISO 1133.

I. Lamination Process 1:

The laminate layers described below are stacked (laid up) to form thepre-laminate assembly described within the examples. For the assemblycontaining a film layer as the incident or back-sheet layer, a coverglass sheet is placed over the film layer. The pre-laminate assembly isthen placed within a Meier ICOLAM 10/08 laminator, (Meier VakuumtechnikGmbH, Bocholt, Germany). The lamination cycle includes an evacuationstep (vacuum of 3 in·Hg) of 5.5 minutes and a pressing stage (pressureof 2 bar) of 5.5 minutes at a temperature of 115° C. For Examples 11,16, 20, 52, 57 and 60 only, an additional step at 145° C. for 5 minuteswhile maintaining the pressing conditions is incorporated to cure thecomposition. The laminate is then removed.

II. Lamination Process 2:

The laminate layers described below are stacked (laid up) to form thepre-laminate assemblies described within the examples. For the assemblycontaining a film layer as the incident or back-sheet layer, a coverglass sheet is placed over the film layer. The pre-laminate assembly isthen placed within a vacuum bag, the vacuum bag is sealed and a vacuumis applied to remove the air from the vacuum bag. The bag is placed intoan oven and heated to 90-100° C. for 30 minutes to remove any aircontained between the assembly. The pre-press assembly is then subjectedto autoclaving at 115° C. for 30 minutes in an air autoclave to apressure of 200 psig (14.8 bar), as described above. The air is thencooled while no more air is added to the autoclave. After 20 minutes ofcooling when the air temperature reaches less than about 50° C., theexcess pressure is vented, and the laminate is removed from theautoclave.

Examples 1-20

The 12×12 in (305×305 mm) laminate structures described below in Table 1are assembled and laminated by Lamination Process 1.

TABLE 1 Laminate Structures Example Layer 1 Layer 2 Layer 3 Layer 4Layer 5  1, 21 Glass 1 ION 1 ION 1 Glass 1  2, 22 Glass 1 ION 2 Glass 1 3, 23 Glass 1 ION 2 ION 2 Glass 1  4, 24 Glass 2 ION 3 PET 1 ION 3Glass 2  5, 25 Glass 3 ION 4 EBA ION 4 Glass 1  6, 26 Glass 1 ION 5 ION5 PET 2  7, 27 Glass 2 ION 6 PET 3 EVA Glass 2  8, 28 Glass 1 ION 7 PET1  9, 29 Glass 1 ION 8 PET 4 PVB A Glass 1 10, 30 Glass 2 ION 9 PET 5PVB PET 1 11, 31 Glass 1 ION 10 ION 11 ION 10 Glass 1 12, 32 Glass 2 ION12 ION 12 PET 1 13, 33 Glass 1 ION 13 PET 6 ION 13 Glass 1 14, 34 Glass1 ION 14 ION 11 ION 14 Glass 1 15, 35 Glass 3 ION 15 PET 1 ION 15 Glass2 16, 36 Glass 1 ION 16 ION 11 ION 16 Glass 1 17, 37 Glass 1 ION 17 PET2 ION 17 Glass 1 18, 38 Glass 2 ION 18 PET 4 ION 18 Glass 2 19, 39 Glass3 ION 19 ION 19 Glass 1 20, 40 Glass 1 ION 20 Glass 1

-   -   ION 1 is a 20 mil (0.51 mm) thick embossed sheet of Ionomer A, a        poly(ethylene-co-methacrylic acid) containing 15 wt % of        polymerized residues of methacrylic acid that is 20% neutralized        with zinc ion and having a MI of 30 g/10 min.    -   ION 2 is a 60 mil (1.52 mm) thick embossed tri-layer sheet        having (i) two (2) 2 mil (0.06 mm) thick surface layers formed        of a blend of Ionomer B, a poly(ethylene-co-methacrylic acid)        containing 18 wt % of polymerized residues of methacrylic acid        that is 10% neutralized with sodium ion and having a MI of 50        g/10 min, and 0.15 wt % of TINUVIN 328 (Ciba Specialty Chemicals        Company), based on the total weight of the blend, and (ii) a        core layer formed of a poly(ethylene-co-methacrylic acid)        containing 18 wt % of polymerized residues of methacrylic acid        that is 35% neutralized with sodium ion and having a MI of 1        g/10 min.    -   ION 3 is a 15 mil (0.38 mm) thick embossed tri-layer sheet        having (i) two (2) 1 mil (0.03 mm) thick surface layers of        Ionomer C, a poly(ethylene-co-methacrylic acid) containing 19 wt        % of polymerized residues of methacrylic acid that is 7.5%        neutralized with zinc ion and having a MI of 100 g/10 min        and (ii) a core layer of a poly(ethylene-co-isobutyl        acrylate-co-methacrylic acid) containing 10 wt % of polymerized        residues of isobutyl acrylate and 10 wt % of polymerized        residues of methacrylic acid that is 70% neutralized with zinc        ions and having a MI of 1 g/10 min.    -   ION 4 is a 1 mil (0.03 mm) thick film of Ionomer D, a        poly(ethylene-co-methacrylic acid) containing 19 wt % of        polymerized residues of methacrylic acid that is 5% neutralized        with zinc ion and having a MI of 200 g/10 min.    -   ION 5 is a 20 mil (0.51 mm) thick embossed sheet of Ionomer E, a        poly(ethylene-co-methacrylic acid) containing 22 wt % of        polymerized residues of methacrylic acid that is 7.5%        neutralized with zinc ion and having a MI of 75 g/10 min.    -   ION 6 is a 20 mil (0.51 mm) thick embossed sheet of Ionomer F, a        composition comprising 99.5 wt % of Ionomer A and 0.5 wt % of        N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane, based on        the total weight of the composition.    -   ION 7 is a 90 mil (2.25 mm) thick embossed tri-layer sheet        having (i) two (2) 1 mil (0.03 mm) thick surface layers of        Ionomer G, a composition comprising 99.25 wt % of Ionomer B and        0.25 wt % of        N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane, based on        the total weight of the composition, and (ii) a core layer of a        poly(ethylene-co-n-butyl acrylate) containing 35 wt % of        polymerized residues of n-butyl acrylate and having a MI of 3        g/10 min.    -   ION 8 is a 20 mil (0.51 mm) thick embossed tri-layer sheet        having (i) two (2) 2 mil (0.06 mm) thick surface layers of        Ionomer H, a composition comprising 99.875 wt % of Ionomer C and        0.125 wt % of        N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane, based on        the total weight of the composition, and (ii) a core layer of a        poly(ethylene-co-methacrylic acid) containing 22 wt % of        polymerized residues of methacrylic acid that is 35% neutralized        with sodium ion and having a MI of 1.5 g/10 min.    -   ION 9 is a 15 mil (0.38 mm) thick embossed sheet of Ionomer I, a        composition comprising 99.875 wt % of Ionomer D and 0.125 wt %        of gamma-glycidoxypropyltriethoxysilane, based on the total        weight of the composition.    -   ION 10 is a 1 mil (0.03 mm) thick film of Ionomer J, a        composition comprising 99.875 wt % of Ionomer E, 0.30 wt % of        TINUVIN 1577, 0.30 wt % of CHIMASSORB 944, (products of the Ciba        Specialty Chemicals Company), and 0.125 wt % of        gamma-methacryloxypropyltrimethoxysilane, based on the total        weight of the composition.    -   ION 11 is a 90 mil (2.25 mm) thick embossed sheet of Ionomer K,        a composition comprising 98.5 wt % of Ionomer A and 1.5 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition.    -   ION 12 is a 15 mil (0.38 mm) thick embossed sheet of Ionomer L,        a composition comprising 98.0 wt % of Ionomer B and 2.0 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition.    -   ION 13 is a 20 mil (0.51 mm) thick embossed sheet of Ionomer M,        a composition comprising 97.5 wt % of Ionomer C, 0.5 wt % of        CYASORB UV-1164 (Cytec Industries), and 2.5 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition.    -   ION 14 is a 1 mil (0.03 mm) thick film of Ionomer N, a        composition comprising 93.0 wt % of Ionomer D, 5.0 wt % of        triallyl isocyanurate and 2.0 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition.    -   ION 15 is a 20 mil (0.51 mm) thick embossed tri-layer sheet        having (i) two (2) 1 mil (0.03 mm) thick surface layers of        Ionomer 0, a composition comprising 95.0 wt % of Ionomer E, 3 wt        % of trimethylolpropane triacrylate and 2.0 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition and (ii) a core layer of        poly(ethylene-co-methyl acrylate) containing 25 wt % of        polymerized residues of methyl acrylate and having a MI of 5        g/10 min.    -   ION 16 is a 1 mil (0.03 mm) thick film of Ionomer P, a        composition comprising 98.0 wt % of Ionomer A, 0.5 wt % of        vinyltrimethoxysilane, and 1.5 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition.    -   ION 17 is a 20 mil (0.51 mm) thick embossed sheet of Ionomer Q,        a composition comprising 97.75 wt % of Ionomer B, 0.25 wt % of        gamma-methacryloxypropyltrimethoxysilane, and 2.0 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition.    -   ION 18 is a 15 mil (0.38 mm) thick embossed tri-layer sheet        having (i) two (2) 1 mil (0.03 mm) thick surface layers of        Ionomer R, a composition comprising 97.375 wt % of Ionomer C,        0.125 wt % of        N-beta-(N-vinylbenzylaminoethyl)-gamma-aminopropyltrimethoxysilane,        and 2.5 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition and (ii) a core layer of a        poly(ethylene-co-methacrylic acid) containing 18 wt % of        polymerized residues of methacrylic acid that is 70% neutralized        with sodium ion and having a MI of 1.5 g/10 min.    -   ION 19 is a 20 mil (0.51 mm) thick embossed tri-layer sheet        having (i) two (2) 2 mil (0.06 mm) thick surface layers of        Ionomer S, a composition comprising 92.875 wt % of Ionomer D,        5.0 wt % of triallyl isocyanurate, 0.125 wt % of        gamma-methacryloxypropyltrimethoxysilane, and 2.0 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition and (ii) a core layer of a        poly(ethylene-co-methacrylic acid) containing 22 wt % of        polymerized residues of methacrylic acid that is 35% neutralized        with zinc ion and having a MI of 0.5 g/10 min.    -   ION 20 is a 90 mil (2.25 mm) thick embossed sheet of Ionomer T,        a composition comprising 94.875 wt % of Ionomer E, 3 wt % of        trimethylolpropane triacrylate, 0.125 wt % of        N-beta-(N-vinylbenzylaminoethyl)-gamma-aminopropyltrimethoxysilane,        CYASORB UV-1164, TINUVIN 123, and 2.0 wt % of        1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, based on the        total weight of the composition.    -   PVB A is a 40 mil (1.02 mm) thick acoustic poly(vinyl butyral)        sheet containing 100 parts per hundred (pph) poly(vinyl butyral)        with a hydroxyl number of 15 and plasticized with 48.5 pph        plasticizer tetraethylene glycol diheptanoate, prepared in a way        similar to those disclosed in PCT Patent Application No. WO        2004/039581.

Examples 21-40

The 12×12 in (305×305 mm) solar cell laminate structures described abovein Table 1 are assembled and laminated by Lamination Process 2, above.

Examples 41-60

The 12×12 in (305×305 mm) solar cell pre-laminate structures describedbelow in Table 2 are assembled and laminated by Lamination Process 1,above. Layers 1 and 2 constitute the incident layer and the front-sheetencapsulant layer, respectively, and Layers 4 and 5 constitute theback-sheet encapsulant layer and the backing layer, respectively.

TABLE 2 Solar Cell Pre-Lamination Structures Example Layer 1 Layer 2Layer 3 Layer 4 Layer 5 41, 61 Glass 4 ION 1 Solar Cell 1 ION 1 FPF 42,62 Glass 4 EVA Solar Cell 2 ION 2 Glass 1 43, 63 Glass 4 ION 3 SolarCell 3 ION 2 AL 44, 64 Glass 2 ION 3 Solar Cell 4 ION 3 Glass 2 45, 65FPF ION 4 Solar Cell 1 ION 4 FPF 46, 66 Glass 1 ION 5 Solar Cell 2 ION 5PET 1 47, 67 Glass 4 ION 6 Solar Cell 3 ION 6 FPF 48, 68 Glass 4 ION 6Solar Cell 4 ION 7 PET 1 49, 69 Glass 4 ION 8 Solar Cell 1 ION 8 Glass 150, 70 Glass 4 ION 9 Solar Cell 2 ION 9 FPF 51, 71 FPF ION 10 Solar Cell3 ION 10 FPF 52, 72 Glass 2 ION 12 Solar Cell 4 ION 11 Glass 2 53, 73Glass 4 ION 13 Solar Cell 1 ION 13 FPF 54, 74 FPF ION 14 Solar Cell 2ION 14 PET 1 55, 75 Glass 4 ION 15 Solar Cell 3 ION 15 AL 56, 76 FPF ION16 Solar Cell 4 ION 16 FPF 57, 77 Glass 4 ION 17 Solar Cell 1 ION 17Glass 1 58, 78 Glass 4 ION 18 Solar Cell 2 ION 18 FPF 59, 79 FPF ION 19Solar Cell 3 ION 19 AL 60, 80 Glass 4 ION 19 Solar Cell 4 ION 20

Examples 61-80

The 12×12 in (305×305 mm) solar cell pre-laminate structures describedabove in Table 2 are assembled and laminated by Lamination Process 2,above. Layers 1 and 2 constitute the incident layer and the front-sheetencapsulant layer, respectively, and Layers 4 and 5 constitute theback-sheet encapsulant layer and the backing layer, respectively.

Comparative Example CE1 Example 81

In Comparative Example CE1, 50 grams of a low melt flow ionomer, whichwas a poly(ethylene-co-methacrylic acid) copolymer containing 15 wt %polymerized residues of methacrylic acid that is 23% neutralized withzinc ions and having a MI of 5 g/10 min, was added to a 90° C. preheatedBrabender Rheometer (C. W. Brabender Instruments, Inc., So. Hackensack,N.J.) equipped with a 50 cc mixing head over 1 minute, while the speedof the mixing blades was set at 8 rpm. The speed of the mixing bladeswas then increased to 30 rpm and the polymer resin was further mixed for1 minute, after which the shear pin sheared due to high torque and themixing motor was at 5 amps. The process was then shut down.

In Example 81, 50 grams of a high melt flow ionomer, which was apoly(ethylene-co-methacrylic acid) copolymer containing 15 wt %polymerized residues of methacrylic acid that is 11.9% neutralized withzinc ions and having a MI of 100 g/10 min, was added to a 90° C.preheated Brabender Rheometer equipped with a 50 cc mixing head over 1minute, while the speed of the mixing blades was set at 8 rpm. The speedof the mixing blades was then increased to 30 rpm and the polymer resinwas further mixed for 5 minutes, after which a homogeneous polymer meltwas achieved with the mixing motor at 1 amp and the polymer melttemperature at 101° C. The process was shut down.

These results demonstrated that high melt flow ionomers (Example 81) canbe compounded at temperatures low enough (about 90° C.) for theincorporation of organic peroxides through commercially-viable andscalable extrusion compounding equipment while the corresponding lowmelt flow ionomers (Comparative Example CE1) can not.

1-19. (canceled)
 20. A process of manufacturing an article, wherein thearticle is a solar cell module, the process comprising: (i) providing asolar cell pre-laminate assembly, said solar cell prelaminate assemblycomprising a polymeric film or sheet; a solar cell component; and anadditional layer; wherein said polymeric film or sheet comprises anionomeric composition comprising an ionomeric copolymer of an alphaolefin and about 1 to about 30 wt % of alpha,beta-ethylenicallyunsaturated carboxylic acid having 3 to 8 carbons, based on the totalweight of the ionomeric copolymer, wherein the carboxylic acid isneutralized to a level of 1 to 100 mol %, with one or more metal ions,based on the total number of moles of carboxylate groups in theionomeric copolymer, and wherein the ionomeric copolymer has a MeltIndex of about 20 to about 300 g/10 min; wherein said solar cellcomponent comprises one or a plurality of solar cells; and wherein saidadditional layer is selected from the group consisting of glass, otherpolymeric interlayer sheets, polymeric film layers, and metal films orsheets; and (ii) laminating the pre-laminate assembly to form the solarcell module.
 21. The process of claim 20, wherein the step (ii) oflamination is conducted by subjecting the assembly to heat and,optionally, vacuum. 23-25. (canceled)
 26. A process for making alaminate, said process comprising the steps of: providing a polymericfilm or sheet, said polymeric film or sheet consisting essentially of anionomeric composition; wherein said polymeric film or sheet is formedfrom a melt of the ionomeric composition, wherein said melt is processeda temperature sufficiently low to prevent premature cross-linking in theionomeric composition, and wherein said ionomeric composition consistsessentially of: an ionomeric copolymer consisting essentially ofcopolymerized repeat units of ethylene; about 10 to about 30 wt %, ofcopolymerized repeat units of at least one alpha,beta-ethylenicallyunsaturated carboxylic acid having 3 to 8 carbons; and 0 to about 50 wt% of copolymerized repeat units of one or more other unsaturatedcomonomers selected from the group consisting of methyl acrylate, methylmethacrylate, ethyl acrylate, ethyl methacrylate, isopropyl acrylate,isopropyl methacrylate, butyl acrylate and butyl methacrylate; whereinthe weight percentages are based on the total weight of the ionomericcopolymer; wherein the ionomeric copolymer is neutralized to a level of1 to 100 mol %, based on the total number of moles of carboxylate groupsin the ionomeric copolymer, and further comprises one or more metalions; and wherein the ionomeric copolymer has a Melt Index of about 20to about 300 g/10 min, as measured by ASTM D1238 at 190° C. and under aload of 2160 g; about 0.5 to about 3 wt % of at least one organicperoxide, based on the total weight of the ionomeric composition;optionally about 0.01 to about 5 wt % of one or more silane couplingagents, based on the total weight of the ionomeric composition; andoptionally one or more additives selected from the group consisting ofinitiators, inhibitors, plasticizers, processing aides, flow enhancingadditives, lubricants, pigments, dyes, flame retardants, impactmodifiers, nucleating agents, antiblocking agents, thermal stabilizers,UV absorbers, UV stabilizers, hindered amine light stabilizers,dispersants, surfactants, chelating agents, coupling agents, adhesives,primers, reinforcement additives and fillers; laying up the polymericfilm or sheet with a solar cell component comprising one or a pluralityof solar cells or with at least one additional layer to form apre-laminate assembly; subjecting the pre-laminate assembly to heat andoptionally vacuum or pressure to form the laminate; and heating thelaminate at a temperature sufficient to cause the peroxide to cross-linkand cure the ionomeric composition.
 27. The process of claim 26, whereinthe melt is processed at a temperature of about 100° C. or less toprevent premature cross-linking in the ionomeric composition.
 28. Theprocess of claim 26, wherein the laminate is heated at a temperature of145° C. or more to cause the peroxide to cross-link and cure theionomeric composition.
 29. A laminate made by the process of claim 26.30. The process of claim 26, wherein the laminate is a safety glasslaminate or a solar cell module.
 31. The process of claim 26, whereinthe laminate is a safety glass laminate, and the at least one additionallayer is a rigid sheet; and further wherein the safety glass laminateoptionally comprises one or more other additional layers selected fromthe group consisting of a second rigid sheet, a film or sheet comprisinga material selected from the group consisting of acid copolymers andionomers derived therefrom, poly(ethylene vinyl acetate)s, poly(vinylacetal)s, polyurethanes, polyvinylchlorides, polyethylenes, polyolefinblock elastomers, ethylene acrylate ester copolymers, siliconeelastomers, epoxy resins, metal foils, polyesters, poly(ethylenenaphthalate)s, polycarbonates, polyolefins, norbornene polymers,polystyrenes, styrene-acrylate copolymers, acrylonitrile-styrenecopolymers, polysulfones, nylons, acrylics, cellulose acetates,cellophanes, and fluoropolymers.
 32. The process of claim 26, whereinthe laminate is a solar cell module that comprises the solar cellcomponent; and further wherein the solar cell module optionallycomprises one or more other additional layers selected from the groupconsisting of an incident layer, a backing layer, an encapsulant, abarrier layer, a dielectric layer, and a scrim.
 33. The process of claim31, wherein the rigid sheet is a glass sheet and the pre-laminateassembly comprises layers laid up in an order selected from the groupconsisting of: glass/ION; glass/ION/film; glass/ION/glass;glass/ION/film/ION/glass; and glass/ION/film/ION/film; wherein the filmcomprises a material selected from the group consisting of acidcopolymers and ionomers derived therefrom, poly(ethylene vinylacetate)s, poly(vinyl acetal)s, polyurethanes, polyvinylchlorides,polyethylenes, polyolefin block elastomers, ethylene acrylate estercopolymers, silicone elastomers, epoxy resins, metal foils, polyesters,poly(ethylene naphthalate)s, polycarbonates, polyolefins, norbornenepolymers, polystyrenes, styrene-acrylate copolymers,acrylonitrile-styrene copolymers, polysulfones, nylons, acrylics,cellulose acetates, cellophanes, and fluoropolymers; and wherein “ION”represents the polymeric film or sheet.
 34. The process of claim 32,wherein the pre-laminate assembly comprises layers laid up in an orderselected from the group consisting of: glass/ION/solar cell/ION/glass;glass/ION/solar cell/ION/fluoropolymer film; fluoropolymerfilm/ION/solar cell/ION/glass; fluoropolymer film/ION/solarcell/ION/fluoropolymer film; glass/ION/solar cell/ION/polyester film;fluoropolymer film/ION/solar cell/ION/polyester film; glass/ION/solarcell/ION/barrier coated film/ION/glass; fluoropolymer film/ION/barriercoated film/ION/solar cell/ION/barrier coated film/ION/fluoropolymerfilm; glass/ION/solar cell/ION/aluminum stock; fluoropolymerfilm/ION/solar cell/ION/aluminum stock; glass/ION/solarcell/ION/galvanized steel sheet; glass/ION/solar cell/ION/polyesterfilm/ION/aluminum stock; fluoropolymer film/ION/solar cell/ION/polyesterfilm/ION/aluminum stock; glass/ION/solar cell/ION/polyesterfilm/ION/galvanized steel sheet; fluoropolymer film/ION/solarcell/ION/polyester film/ION/galvanized steel sheet; glass/ION/solarcell/acoustic poly(vinyl butyral) encapsulant layer/glass;glass/ION/solar cell/poly(vinyl butyral) encapsulant layer/fluoropolymerfilm; fluoropolymer film/ION/solar cell/acid copolymer encapsulantlayer/Tedlar® film; glass/ION/solar cell/ethylene vinyl acetateencapsulant layer/polyester film; fluoropolymer film/ION/solarcell/poly(ethylene-co-methyl acrylate) encapsulant layer/polyester film;and glass/poly(ethylene-co-butyl acrylate) encapsulant layer/solarcell/ION/barrier coated film/poly(ethylene-co-butyl acrylate)encapsulant layer/glass; wherein “ION” represents the polymeric film orsheet.
 35. The process of claim 26, wherein the at least one organicperoxide is selected from the group consisting of2,5-dimethylhexane-2,5-dihydroperoxide,2,5-dimethyl-2,5-di(tert-betylperoxy)hexane-3, di-tert-butyl peroxide,tert-butylcumyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane,dicumyl peroxide, alpha,alpha′-bis(tert-butyl-peroxyisopropyl)benzene,n-butyl-4,4-bis(tert-butylperoxy)valerate,2,2-bis(tert-butylperoxy)butane, 1,1-bis(tert-butyl-peroxy)cyclohexane,1,1-bis(tert-butylperoxy)-3,3,5-trimethyl-cyclohexane, tert-butylperoxybenzoate, and benzoyl peroxide.
 36. The process of claim 26,wherein the ionomeric composition comprises the one or more silanecoupling agents, said silane coupling agent(s) selected from the groupconsisting of gamma-chloropropylmethoxysilane, vinyltrimethoxysilane,vinyltriethoxysilane, vinyltris(beta-methoxyethoxy)silane,gamma-vinylbenzylpropyltrimethoxysilane,N-beta-(N-vinylbenzylaminoethyl)-gamma-aminopropyltrimethoxysilane,gamma-methacryloxypropyl trimethoxysilane, vinyltriacetoxysilane,gamma-glycidoxypropyltrimethoxysilane,gamma-glycidoxypropyltriethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, vinyltrichlorosilane,gamma-mercaptopropylmethoxysilane, gamma-aminopropyltriethoxysilane, andN-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane.
 37. The processof claim 26, wherein the ionomeric composition comprises the initiatorand the initiator comprises dibutyltin dilaurate, or wherein theionomeric composition comprises one or more inhibitors selected from thegroup consisting of hydroquinone, hydroquinone monomethyl ether,p-benzoquinone, and methylhydroquinone.
 38. The process of claim 26,wherein the ionomeric copolymer has a Melt Index of about 75 to about200 g/10 min.
 39. The process of claim 26, wherein the at least onealpha,beta-ethylenically unsaturated carboxylic acid is selected fromthe group consisting of acrylic acid and methacrylic acid; the ionomericcopolymer comprises about 10 to about 25 wt % of thealpha,beta-ethylenically unsaturated carboxylic acid; and the ionomericcopolymer is neutralized to a level of 2 to 40 mol %.
 40. The process ofclaim 26, wherein the ionomeric composition consists essentially of theionomeric copolymer; and about 1.5 to about 3 wt % of the organicperoxide; wherein the ionomeric copolymer consists essentially of thecopolymerized repeat units of ethylene and about 15 to about 23 wt % ofcopolymerized repeat units of acrylic acid, methacrylic acid, or acrylicacid and methacrylic acid; and wherein the ionomeric copolymer has aMelt Index of about 30 to about 200 g/10 min.
 41. The process of claim26, wherein the at least one alpha,beta-ethylenically unsaturatedcarboxylic acid is selected from the group consisting of acrylic acidand methacrylic acid; the ionomeric copolymer comprises about 15 toabout 23 wt % of the copolymerized repeat units of the at least onealpha,beta-ethylenically unsaturated carboxylic acid; and the ionomericcopolymer is neutralized to a level of 2 to 40 mol %.
 42. The process ofclaim 26, wherein; the alpha,beta-ethylenically unsaturated carboxylicacid is selected from the group consisting of acrylic acid andmethacrylic acid; the ionomeric copolymer comprises about 18 to about 23wt % of the copolymerized repeat units of the at least onealpha,beta-ethylenically unsaturated carboxylic acid; the ionomericcopolymer is neutralized to a level of 2 to 20 mol %; and the at leastone organic peroxide is selected from the group consisting of2,5-dimethylhexane-2,5-dihydroperoxide,2,5-dimethyl-2,5-di(tert-betylperoxy)hexane-3, di-tert-butyl peroxide,tert-butylcumyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane,dicumyl peroxide, alpha,alpha′-bis(tert-butyl-peroxyisopropyl)benzene,n-butyl-4,4-bis(tert-butylperoxy)valerate,2,2-bis(tert-butylperoxy)butane, 1,1-bis(tert-butyl-peroxy)cyclohexane,1,1-bis(tert-butylperoxy)-3,3,5-trimethyl-cyclohexane, tert-butylperoxybenzoate, and benzoyl peroxide.
 43. The process of claim 26,wherein the one or more additives are selected from the group consistingof: about 0.01 to about 0.05 wt % of the initiator dibutyltin dilaurate;up to about 5 wt % of one or more inhibitors, said inhibitor(s) selectedfrom the group consisting of hydroquinone, hydroquinone monomethylether, p-benzoquinone, and methylhydroquinone; about 0.05 wt % up toabout 5 wt % of the thermal stabilizer; about 0.05 wt % to about 5 wt %of the UV absorber; and about 0.05 wt % to about 5 wt % of the hinderedamine light stabilizer; wherein the weight percentages are based on thetotal weight of the ionomeric composition.